Single web grid with reinforced bulb

ABSTRACT

Manufacture of roll formed one piece sheet metal grid tees that affords different load ratings with the same gauge and quality of sheet stock and the same overall cross-section dimensions by varying the width of the strip used to make the tees and disposing material added for increased load rating at the area of the hollow reinforcing bulb of the tees.

The invention relates to grid tees for suspended ceilings and, inparticular, to an improved grid tee construction and method of itsproduction.

PRIOR ART

Suspended ceilings typically use a rectangular metal grid made up ofmain runners and cross runners. The grid supports ceiling panels ortiles normally laid onto the upper faces of runner or tee flanges or,less commonly, large panels are screwed to lower faces of the flanges.The runners commonly have an inverted T-shaped cross-section and aretypically roll-formed from strips of sheet metal. The lower flangeportions of the tee section extend horizontally from both sides of avertical central web. The upper edge of the web is conventionallyreinforced with a hollow bulb.

The grid runners or tees are supplied in different strengths, e.g.intermediate and heavy duty, to satisfy the requirements of a particularinstallation. The specified strength or rating can depend, for example,on the use of a space below the ceiling, seismic conditions, and soforth. The industry currently recognizes an intermediate duty loadrating and a higher capacity “heavy duty” load rating.

The cross-sectional geometry of conventional grid tee runners isrelatively standard, commonly being 1½″ high, 15/16″ wide and having areinforcing bulb width of ¼″. Suspended ceiling grid is in a nearcommodity status and sales of the same can be largely price driven.Therefore, it is imperative for a manufacturer to put no more material,i.e. steel, in the product, than is necessary to meet a customer'sneeds. The strength of a grid tee is directly related to the gauge orthickness of the sheet metal used in its production. Where a lighterduty product is being made, a lighter or thinner gauge sheet metal stockcan be used and where a heavier duty product is called for, a heaviergauge metal strip can be used to produce the grid tee. The commonpractice of producing different rated grid tees by changing thethickness of the stock used to make the tees has certain costsassociated with the labor and manufacturing down time necessary forchanging over and adjusting the roller dies that are used for differentgauges of sheet stock. Additionally, a manufacturer can be forced to buyand inventory multiple gauges of sheet steel for producing grid tees ofdifferent load ratings when following prior art practices.

SUMMARY OF THE INVENTION

The invention provides a novel method for producing grid tee runners andnovel runners produced by such method. The disclosed method enables amanufacturer to produce grid tees of different load ratings while havingthe same overall roll formed configuration and being constructed of thesame gauge or thickness of sheet metal. More particularly, the inventionis applicable to the inverted tee style of grid runner that has a singlelayer web and, ordinarily, is formed of a single strip of sheet metal.With the invention, additional strength, beyond the load capacity orrating attainable with a conventional configuration and a given gaugeand quality of material is obtained by constructing the grid teereinforcing bulb with at least a partial double layer of sheet material.

The invention approaches an ideal construction because it locates thematerial added for increased strength into the area of the bulb. This isadvantageous since the additional material is situated as far or nearlyas far as possible from the neutral axis, located near the mid-height ofthe web, thereby obtaining a high beam strength.

Where the double layer extends along less than the full perimeter of thereinforcing bulb, it can be arranged, more or less, on either side ofthe plane of the web relative to a flange construction that is halfdouble layer and essentially half single layer. The invention, byutilizing the same gauge of material, for different duty ratings,enables the manufacturer to reduce its costs of production. Theinvention permits the manufacturer to keep the material content as lowas practical and at the same time allows certain labor costs and machinedown time to be avoided. Labor costs and machine down time are minimizedsince there is no need to change over the rolling dies to run differentgauges of strip stock.

The invention can extend the versatility of existing tooling since itcan allow manufacture of higher duty products, even though such toolingis limited to running lighter gauge material. Down time or change overtime to run higher or lower duty product in a roll forming machine isvirtually eliminated with the invention since the only changeessentially required is that of changing the width of the stock beingfed to the machine. Economy can also be gained with the invention sincethe material used for different load ratings need only vary in width.This enables the grid runner manufacturer to buy and inventory mastercoils of one gauge and to simply slit such roll stock to the widthsneeded. The disclosed grid can be easier to install and, therefore, hasgreater marketability because it is easier to field cut the web by handwith a tin snips, for example, than to cut grid tee made with heavierstock.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross-sectional view of one style of a known prior art gridtee;

FIG. 2 is a fragmentary cross-sectional view of the upper part of a gridtee modified in accordance with the invention;

FIG. 3 is a fragmentary cross-sectional view of the upper part of a gridtee in accordance with another modification of the invention;

FIG. 4 is a fragmentary cross-sectional view of another form of a gridtee with a single layer bulb;

FIG. 5 is a fragmentary cross-sectional view of the upper part of a gridtee in accordance with still another modification of the invention;

FIG. 6 is a fragmentary cross-sectional view of the upper part of a gridtee in accordance with a further modification of the invention; and

FIG. 7 is a fragmentary cross-sectional view of the upper part of a gridtee in accordance with a still further modification of the invention.

DESCRIPTION OF THE PREFERRED EMBODIMENT

The invention pertains to a method of producing sheet metal grid runnersof the inverted tee style. The grid runner tees are used in constructionof suspended ceilings, soffits, and like structures. FIG. 1 shows aconventional prior art grid runner tee 10 in cross-section. The grid teeor runner 10 is roll-formed from a sheet metal strip 11, such as0.021/0.024″ gauge galvanized steel, for example. It will be understoodthat other gauges and other metals such as aluminum can be used inpracticing the invention. The tee 10 is shaped from a flat strip in aconventional roll forming machine in which rolls, sometimes referred toas dies or tooling, at successive stages or stations along the rollingdirection progressively form the strip into the desired form. Materialadjacent opposite edges 12, 13 of the strip 11 in this tee shape as wellas those described below, can be shaped concurrently as the strip 11progresses through the roll forming machine. The tee 10 as well as othertees disclosed herein, if it is a main tee, can have nominal lengths of10 feet or 12 feet, and if it is a cross tee or runner, can have nominallengths of 2 feet or 4 feet. The tee 10, apart from separately formedend connectors (not shown) fixed to its ends as is known in the art, ispreferably of a one-piece construction. In use, the grid tee 10 has theconfiguration of an inverted letter T with a lower flange 15, an upperhollow reinforcing bulb 16, and a single layer web 17 connecting theflange 15 to the bulb 16. The illustrated tees in the various figuresare customarily, suspended by wires from overlying superstructure andlooped through holes in the web, can be used with ceiling panels ortiles laid-in on top faces of the flanges 15 or with drywall or likepanels screwed to the bottom faces of the flanges.

The various grid tees disclosed herein preferably though notnecessarily, have industry standard overall dimensions. If standard, thelower face of the flange 15 is nominally 15/16″ wide, the height of thebulb from the flange is 1½″ and the bulb width is ¼″. Some commerciallyused grid tees of other constructions have taller tees of, for example,1 5/8 ″. In the style of grid tee shown in FIG. 1, as is conventional,the web 17 is a single, planar and vertical layer. The flange 15 has itswidth centered on the plane of the web 17 but is asymmetrical withrespect to the web by virtue of having at one side of the web oneportion 18 of a generally single layer, being associated with the edge12 and, on the opposite side of the web another portion 19 with a doublelayer. A hem at the edge 12, being folded onto the main part of theportion 18, forms a minor double layer area on this flange portion 18.

The illustrated reinforcing bulb 16 has a generally circularcross-section with its center at the plane of the web 17 so that it issymmetrically arranged over the web. As shown, the bulb cross-section issubstantially a fully closed circle with the edge 13 closely adjacent orcontacting a zone 26 where the sheet or strip of metal 11 making the tee10 transitions between an upper region of the web 17 and the bulb 16.This zone 26 is displaced, measuring along the body of the strip 11 inthe width-wise direction of the strip, a distance from the edge 13 aboutthe same as the circumference of the bulb 16.

As mentioned, FIG. 1 represents the configuration of a prior art gridtee 10. In the remaining FIGS. 2-7, the hollow reinforcing bulb andupper region of a web are depicted and it will be understood that thelower part of the respective tee cross-sections is similar or identicalto that shown in FIG. 1.

FIG. 2 illustrates the upper portion of a grid runner or tee 30 with amodified reinforcing bulb 31. Comparison of FIG. 2 with FIG. 1 showsthat the width of the metal strip, designated 32, used to make the tee30 is somewhat greater than the width of the strip 11 used to make thetee 10, it being understood that nominal dimensions of the tees,including the widths of the reinforcing bulbs is the same. Theadditional width of strip material 36 measured from a fold line 33 to anedge 34 is turned back on the remainder of the strip 32 by roller diesand then a hollow bulb 31 is roll-formed in the same manner and sameroller dies as those used to form the bulb 16 of the tee 10 of FIG. 1.The additional width of material is situated in the bulb 31 and followsthe contour and abuts the adjacent portion of the inner periphery of thebulb 31. The result is that the bulb 31 has a partial double wallprovided by the folded-over material 36. The reinforcing bulb 31,ideally, has external dimensions essentially identical to those of thehollow bulb 16 of the grid tee 10.

In FIG. 3 an upper part of another version of a tee 40 is shown. A stripof material 41 wider than the strip 11 of FIG. 1 and the strip 32 ofFIG. 2, is used to make the tee 40. Extra material measured from an edge42 to a fold line 43 adjacent the transition 26 from the web 17 to ahollow bulb 44 is provided. The additional width of material 41, likethe material 36 of the grid tee 30 of FIG. 2, abuts an inner surface ofan outer layer or wall of the bulb 44 and, in this version, provides asubstantially full double layer bulb, i.e. the full circumferentialextent of the bulb comprises a double layer of metal sheet stock.

FIGS. 4 and 5 illustrate grid tees 45, 46 with hollow reinforcing bulbs47, 48 that have oval or O-shaped cross-sections. Comparison of FIG. 5with FIG. 4 shows that the same concept of making a reinforcing bulb 46with a partial double layer 49 is applicable to bulb configurationsother than the round configuration of FIGS. 1-3. Sometimes in practice,the double wall portion 49 may spring away from the outer bulb walltowards the center of the bulb 48 but this condition does not appear tosignificantly adversely affect the performance of the tee 46. An ovalbulb configuration with a full double layer is also contemplated.

FIG. 6 illustrates the upper portion of still another form of grid tee50. The grid tee 50 includes a hollow bulb 51 that is circular and has apartial double layer 52 formed by an additional strip width portionexisting between an edge 53 and a point 54 adjacent the transition zone26. While not shown, it is contemplated that a tee similar to the tee 50can be formed with a full double layer extending about the full innerperiphery of the bulb. In either the case of FIG. 6 or a tee with asimilar double layer or wall, the additional layer is in a scroll-likerelation with the outer layer, designated 56 of the bulb 51. The hollowreinforcing bulb 51 with a partial or full double layer is made on thesame roll-forming dies that can be used to form the tee 10 of FIG. 1,the double layer section 55 of the reinforcing bulb being rolled priorto the formation of the outer bulb layer 56. Again, the double layerbulb style grid tee can be made in a production run on the roll-formingline using a specific width of a strip of a given thickness and thesingle layer version of the tee can be made on the same line with anarrower strip of the same thickness during a different production run.

FIG. 7 illustrates a grid tee 60 modified from the grid tee 10 of FIG. 1by the addition of a tag element 61 that is integral with a hollowreinforcing bulb 62. Analogous to the previously described grid tees,the grid tee 60 can be manufactured in production runs on the same rollforming line used in producing the grid tee 10 by increasing the widthof a strip 63 of metal from the width of the strip 11 used to make thetee 10 while using a sheet metal gauge or thickness of essentially thesame dimension.

In the grid tee constructions of FIGS. 2, 3, and 5-7, additional widthof a metal strip is associated with a hollow reinforcing bulb toincrease the duty rating of the respective tee. In general, particularlywhere the additional material is disposed within the reinforcing bulb,the increase in strength can be roughly proportional to the amount ofadditional width of stock used to generate the particular grid tee.

The invention suggests the use of an additional width of sheet metalstrip stock beyond that used to form a single layer web, single layerhollow bulb grid tee, i.e. a conventional grid tee, and to dispose thisadditional, integral width of material as an extension of the singlewall reinforcing bulb so that such extra material is disposed where itis, at least to some extent, remote from the neutral axis of the gridtee, which typically is in a central area or region of the height of aweb. The invention, additionally, comprehends the production of gridtees of similar, or identical external shapes using the same gauge ormaterial stock thickness but with different load capacities by virtue ofhaving a reinforcing bulb of at least a partial double layer in someproduction runs and in other production runs a grid tee with a bulb thatis essentially exclusively a single layer. As discussed, the partial orwholly double wall reinforcing bulb grid tees can be made on the sameroll-forming production tooling as the grid tees such as shown in FIGS.1 and 4 with a single layer reinforcing bulb and, desirably, with thesame thickness or gauge of stock. Other shapes of reinforcing bulbs areenvisioned such as square, rectangular or with an inverted V-shaped top.Similarly, other shapes of grid tees with different webs and flanges areenvisioned. Common to all of the disclosed grid tees that representmodifications from a single layer reinforcing bulb is additionalreinforcing material in the form of an integral, additional width of astrip directly attached to the part of the outer layer of thereinforcing bulb that, measured along the periphery of the cross-sectionof the bulb, is remote from the point of transition between the bulb andweb.

It should be evident that this disclosure is by way of example and thatvarious changes may be made by adding, modifying or eliminating detailswithout departing from the fair scope of the teaching contained in thisdisclosure. The invention is therefore not limited to particular detailsof this disclosure except to the extent that the following claims arenecessarily so limited.

1. A method of manufacturing grid tees of different load ratingscomprising operating a roll-forming line to make grid tees of at leasttwo different load ratings from strips of metal sheet stock ofessentially uniform thickness that is formed into a tee with a singleweb and a hollow bulb, the hollow bulb being made from stock adjacentone edge of the web, increasing the width of the stock strip fed to theroll-forming line in some production runs to increase the load rating ofthe grid tee and decreasing the width of the stock strip fed to theroll-forming line in other production runs to lower the load rating ofthe tee, the additional material of the strip of increased width beingrolled so that it is contiguous with the bulb while causing the externaldimensions of the bulbs of the tees of increased and the decreasedratings to remain essentially the same whereby the grid tees ofdifferent load ratings can be produced on the same roll set without theneed for significant adjustment or substitution of rolls.
 2. A method asset forth in claim 1, wherein the additional material of the strip ofincreased width is formed so that it lies within the bulb.
 3. A methodas set forth in claim 2, wherein the additional material of the strip ofincreased width is formed so that it follows the contour of an outerlayer of the bulb.
 4. A method as set forth in claim 3, wherein theadditional material of the strip of increased width is formed to followthe contour of substantially all of the outer layer of the bulb therebyforming a double layer bulb.
 5. A method as set forth in claim 3,wherein the additional material of the strip of increased width isformed in a scroll-like relation to the outer layer of the bulb.
 6. Agrid tee for a suspended ceiling, soffit, or like structure, the gridtee being of the inverted tee style and being roll-formed from a singlestrip of sheet metal of a selected width, the tee having a lower flange,an upper hollow reinforcing bulb, and a web extending between the flangeand the bulb, the lower flange having portions on each side of the webthat are of generally equal width, at least one of the flange portionsbeing of a double layer, the web being of a single layer, the bulbhaving a width and height, the width being generally centered over theweb, at least a portion of the bulb being a double layer that increasesthe load rating of the tee.
 7. A grid tee as set forth in claim 6,wherein said bulb is curvilinear in section.
 8. A suspended ceiling gridtee as set forth in claim 7, wherein said bulb is round incross-section.
 9. A suspended ceiling grid tee as set forth in claim 7,wherein said bulb is oval in cross-section.
 10. A suspended ceiling gridtee as set forth in claim 6, wherein said double layer bulb portionincludes a fold at a part of the cross-section of the bulb that isremote, as measured along the cross-section, from a point where the bulbtransitions with the web.
 11. A suspended ceiling grid tee as set forthin claim 6, wherein said double layer bulb portion, in cross-section, isscroll-like in relation to an outer layer of the bulb.